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  • This article is being put together to help walk you through the fairly simple steps of replacing the grommets at the fuel return t and the washers on the banjo bolt at the back of the head.

     

    Symptoms that lead me to start changing these parts were...

     

    -Hard starts with the nose of the truck pointed up hill after 4+ hours

    -Loss of prime

    -Longer cranking of the engine

    -Point nose down hill the truck would fire up no problems.

     

    Starting with the T on the fuel return lines.

     

    The easiest way to locate this T is to find your return banjo on the VP44 (looking down at it, it's the one of the left) and follow that hard line towards the back of the engine. Eventually you will find a brass T with one line coming down from the back of the head (we'll cover that later) and another line going down towards to the fuel tank.

    You can use the Part number lookup tool to find the Part Numbers

    The following diagrams might help as well.

     

     

    3945707.jpg

     

    Part #3 in this diagram

     

    Screen shot 2016-04-08 at 9.29.47 PM.png

     

    Part #29 from this diagram. You'll be replacing the grommets that are #32 in this diagram.

     

    It'll look like this

    IMG_3570.JPG

     

    You'll need a 16mm wrench to get the caps off. It's easiest to get all 3 loose to the point where you can unscrew them by hand, that way you avoid the T from spinning. Once off, you can twist the T to let the fuel lines slide out. The end of the fuel lines will have a belled or flared end, like a trumpet or other brass instrument.

     

    It will look like this once out.

     

    IMG_3640.JPG

     

    Old grommets on top, new on bottoms. One thing of note here, the old grommets didn't look that bad. If I wasn't having fuel issues I don't think I would've changed them so keep that in mind.

     

    At the time of this article the cheapest I could find these grommets was from Geno's located HERE part #3905351

     

    From here it'd be a good idea to clean things up a bit with a scotch bright pad or something similar. I cleaned the fuel T and the fuel lines. I sprayed the fuel T with brake cleaner and then dried it off with compressed air.

     

    Re-assembly is the same as taking it apart. Just get the nuts on there loosely at first until all 3 nuts are on the fuel T and then tighten them down equally as you'll see once things get tighter the fuel T will want to move. Tighten the nuts down so they are firmly snug, but not over tightened. Otherwise the nut will just keep compressing the grommet to the point it's ineffective. It helped me to disconnect the oil dipstick and other connectors that are in the area to free up room for wrench operation.

     

    ****************************************************************************************

     

    Next, the washers on the banjo bolt at the back of the head are also culprits which can cause hard starts and loss of prime and if you're experiencing the issues stated before, you might as well replace them.

     

    3945707.jpg

     

    In this diagram the banjo you want it #2 and the washers you'll replace are #4 &#5 which are the same even though listed differently.

     

    **Obviously with a cold engine**

     

    The best way to tackle this job is to get some thick moving blankets and lay them on top of the engine bay and get ready to crawl! While laying on top of the engine, reach around the back of the engine on the left side. You'll be looking (read:feeling) for this.

     

    IMG_3242.JPG

     

    Using a 17mm wrench you can get the banjo off. Remember that righty tighty lefty loosey will be backwards in this instance! You don't want to snap off the banjo in the head!!

     

    Once out, clean up things to help with re-installation.

     

    IMG_3241.JPG

    IMG_3245.JPG

     

    Here is the banjo removed with old washers on the left and new on the right. I got the washers from my local dodge dealership part #05016555AB but you can also get them from Genos HERE

     

    Replacement is straight forward. Just make sure that you get banjo washers on both ends of the banjo.

     

    Like this

     

    IMG_3246.JPG

     

     

    With final installation make sure that you get the banjo bolt tight, but again DO NOT OVER TIGHTEN! The bolts are somewhat fragile and could/will snap off if tightened too much.

     

    IMG_3247.JPG

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    James merritt

       2 of 2 members found this review helpful 2 / 2 members

    This was very helpful, it was a difficult job for me, my hands took a beating and laying on the engine is a chore. When I got done putting in the grommets and banjo washers I put all other things back in order and now it leaks bigger drops and faster. I could drive it with pryer leak but not now. So tomorrow I will look for a problem right below the tee.

    87F68888-5041-43F0-8135-80962C72DE0B.jpeg

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    mattmoselle

    · Edited by mattmoselle

      

    what was the process for getting the grommet over the flare on the fuel return line?

    what is the purpose of the grommet? Shouldn't the flare provide the sealing action?

    Link to comment
    OmahaGen2

      

    Well done, great pics & obviously very easy to understand.  So why not change out the banjo bolt for a easy 90 & a fuel rated hose back to the tank?

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